As a world-leading manufacturer of steel windows, Crittall Windows manufactures a vast range of bespoke windows, doors and screens that range from residential and commercial applications to everything from new buildings to architecturally significant historical buildings. With a proud history that dates back to 1849, the Essex company applies the latest manufacturing technologies to deliver products that are the envy of the industry. In the new machining department, the FX Series of compact oil mist collection systems from Filtermist has made a dramatic impact.
Crittall Windows has a fascinating history that includes producing windows for the fateful Titanic, manufacturing munitions during World War 1 and prefabricated truss bridges for World War 2. However, innovative window manufacture has always been the core business at Crittall, and its production processes incorporate a series of hot-dip galvanising and polyester powder coating to strict BS and ISO: 9001 standards that differentiate the quality and prestige of this brand over its rivals.
The Witham-based manufacturer that exports worldwide has implemented a series of modernisation strategies that have seen Crittall upgrade its machining division. Discussing this, Darren Joyce, Production Director at Crittall Windows says: “We manufacture complete windows and doors – we do everything here. We cut the steel, machine it, weld it, galvanise it, powder coat and ship our products around the world. We are having a transitional period where our older machinery, which was very heavy-duty and made to stamp big slots and holes in steel sections, is now being replaced as the old method isn’t following how we manufacture things nowadays. We now require a lot more one-offs rather than hundreds of parts made to the same size. So, we have moved to more modern and flexible CNC machining to deal with one-offs a lot easier.”
The transition to new manufacturing systems and machines is an ongoing project that has taken a few years but is paying dividends for the company celebrating its 175th anniversary this year. One issue the company recognised from transitioning to CNC machining from older punching and stamping technology was coolant mist and fumes from the machine tools. This is where Filtermist stepped in to solve the problem. Recalling the situation, Darren continues: “One of the biggest challenges we faced when we moved over to CNC machining was that steel profiles are not like aluminium or PVC. Steel takes longer to process and there is a lot of machining that goes on. This needs a lot of coolant and this gave us an issue with the creation of fumes and in particular oil-laden fumes. We rapidly found that the factory was starting to mist up. This wasn’t a good workplace environment for our staff. Additionally, there was far too much coolant on our parts which are being welded further downstream – and this creates even more fumes.”
“We wanted to revise the way we work with coolant and cutting fluid on our machines. One of the biggest challenges was trying to move away from paper-type filters that are used on our type of machine tools. We needed to find something that would take the oil out of the air. If we could take the oil out of the air inside the machines, then when the machine doors open, you don’t get puffs of oil-laden air – giving you a cleaner working environment.”
Alluding to how the company started working with Filtermist, Darren recalls: “We did a lot of investigation work and we spoke to a lot of machinery manufacturers, which brought us to Filtermist. Filtermist effectively manufacture what is a drum that centrifugally spins and removes the oil out of the air and filters it out. We thought it sounded too good to be true – but it works! We have now installed them in all of our CNC machining centres. The Filtermist FX5002 unit successfully spins the oil out of the air, but we have taken that a step further. We have modified further, so we are recycling that oil and using it on our flood-based coolant machines, extending the service life of the oil.”
The company has also applied its innovation to several other areas. As Darren continues: “We have also made changes where the door of the machines open. Now, after a 10-minute time-lapse the machines will cut off, not wasting electricity on equipment that is not being used. We are delighted that we found Filtermist, it’s a fantastic product that does ‘exactly what it says on the tin’.”
Crittall has gone from not knowing the Filtermist brand to having 12 of its FX5002
units installed in less than a year. Furthermore, Crittall has specified the Filtermist units with an F Monitor 2 that gives customers live readings of the Filtermist systems’ efficiency level – notifying staff when service and maintenance is required.
The Filtermist FX5002 is a popular model that is powered by an extremely efficient 1.5kW 60Hz motor that generates an airflow rate of 2000m3/hr at 60Hz. Exceptionally easy to install, operate and maintain, the Filtermist FX5002 is a compact 357mm diameter unit with a height of just 613mm (751.50mm with an after-filter unit).
Commenting upon the evident changes the Filtermist systems have made to the working environment at Crittall, Darren continues: “Not long after installation, we could see the difference. We could see the mist clouds dissipating. The health & safety and well-being of employees have always been our number one priority. In a steel window manufacturing plant where you also have welding operations and pre-treatment processes, there are evidently fumes, so we have large extraction facilities to manage this. However, the localised filtration of oil out of the air by Filtermist was so important – that is where we have seen the biggest improvement. There is no longer any oil on employees’ clothes, on their hands, faces or on the workpieces and it’s not on the floor. So, it’s a much nicer environment and a healthier place for our staff to work in. We have also seen a significant improvement in the air quality checks that we do every year. That has come through in numbers and is based on facts which is even better for our business.”
Of course, the Filtermist systems can add so much more than an improvement to the working environment. Commenting upon this, Darren concludes: “We have also found economic benefits from the Filtermist systems. We take the oil from the Filtermist systems, recycle and use it on other machines – coolants and cutting fluids are not cheap, especially as we have moved to a water-based coolant as opposed to an oil-based coolant. We have to get the water and oil solubility mix correct, so it can burn off without creating too much fume. All in all, if you package all of those things together, you end up with a much healthier working environment. We have also cut down on our oil consumption and expenses. Additionally, the Filtermist filters are cutting in and out to coordinate with our machine usage as opposed to constantly running like extraction units, so we are also seeing energy savings. All of this really does make the Filtermist extraction systems a ‘no-brainer’.”
Visit www.filtermist.co.uk for more details
